Continuous Pyrolysis Plant

Increasing Pressure on Waste Disposal

The world produces about 400 million tons of plastic waste every year. In addition, the world generates more than 30 million tons of scrap tires every year, and the oil industry waste is countless. With the waste growth rate rising, the waste recycling rate is still at a low level. The huge industrial solid waste flow brings unpredictable processing pressure. Therefore, only a high-capacity, continuous pyrolysis plant with no intermittent operation can complete such a huge task of reduction & resource utilization.

Rising Global Emissions Standard

Global environmental regulations are becoming increasingly stringent. For example, the European Union’s Industrial Emissions Directive 2.0 came into effect on August 4, 2024. The policy further tightened emission limits and expanded the scope of supervision of industrial facilities. Intermittent equipment has certain limitations in emission control. In contrast, continuous pyrolysis plant adopts advanced exhaust gas treatment systems to control emissions and meet environmental standards.

Progressive Automation Technology

In recent years, industries have introduced intelligent control solutions combining IoT & PLC. This enables real-time acquisition of process parameters (temperature, pressure, gas composition, etc.), closed-loop regulation, and energy consumption allocation optimization. The integration of these cutting-edge technologies in continuous equipment can greatly improve production stability and operating efficiency. Thus, this meets the trend of intelligentization of modern industrial facilities.

Low Risk Investment Requirement

The efficient production capacity and low operating costs of continuous pyrolysis equipment make the long-term return on investment more attractive. Investors can use by-products (such as syngas to reheat the system) to reduce operating costs. At the same time, tax exemptions, subsidies and carbon offset mechanisms provided by many countries can also significantly shorten the investment payback period. Generally, investors can realize the return of principal within 1-3 years and continue to benefit thereafter.

Raw Material Pretreatment

Continuous pyrolysis reactor has strict requirements on feed size. The waste tyre must be in a rubber powder state, while the feeding size is 1-5mm. We can provide customers with tyre shredding production line. In addition, the feed size of waste plastic is less than 20mm.

Raw Material Feeding

At this stage, the materials enter the inert gas protection system through the conveyor. Later, after discharging the excess air, the material enters the reactor through the feeding screw. According to different material status, we provide the following conveying methods.

• Large-inclination Belt: mainly targeted at solid granular such as tyre rubber powder, plastics particles, and oil sludge with a liquid content of less than 40%.
• Shaftless Screw: oil sludge with a liquid content of 40%-60%.
• Oil Slurry Pump: oil sludge with a liquid content of more than 75%.

Pyrolysis

Before the raw materials enter, the main furnace requires a 3-4 hour preheating period. At this time, the heat source is provided by the burner. When the temperature reaches 300-350°C, the raw materials enter the pyrolysis furnace and the reaction begins. At this time, the organic volatile matter in the raw material begins to decompose into smaller molecules, forming oil gas. The entire reaction process uses controlled hot air heating.

Oil Gas Condensation

The condenser converts the condensable components in the high-temperature oil gas into pyrolysis oil. Firstly, oil gas passes through a three-stage condensation system. The first stage condenser separates heavy impurities in oil gas. Then, the second/third stage condensers collect different distillate products. The opening & closing of different solenoid valves in the oil pumping pipeline can realize separate & mixed collection.

Syngas Recovery

The non-condensable component of oil gas, syngas, enters the water seal. Water seal purifies syngas. Clean syngas enters the secondary combustion chamber through pipes. It is mixed with high-temperature hot air to heat the main furnace.

Exhaust Gas Treatment

BLL-30 equipment adopts with high-end exhaust gas treatment system. The high-temperature exhaust gas generated by the entire reaction enters the chemical tower through the induced draft fan. The chemical tower cools, desulfurizes, and denitrifies the exhaust gas. Subsequently, the flue gas enters the electrostatic precipitator and activated carbon precipitator for dust removal. Eventually, exhaust gas emitted from the chimney meets EU emission standards.

Solid Residue Discharging

The solid residue produced by the reaction is extracted through the first spiral discharger. After passing through two water-cooled dischargers, the solid residue enters the temporary storage tank through a bucket elevator. In the temporary storage tank, circulating water cools the solid residue. When the temperature drops below 60 degrees, the solid residue is discharged from the temporary storage tank.

Pyrolysis Product Sales

Relying on the advancement of production technology of continuous pyrolysis machine, the market prospects for pyrolysis products are optimistic:

• Pyrolysis Oil: With the transformation of traditional energy structure, sustainable energy has gradually become the choice of some enterprises. As an alternative fuel, it is competitive in the fuel market.
• Carbon Black: It is widely used in industries such as tires, plastics, and coatings. The market demand for carbon black is stable, especially in emerging markets with strong growth potential.

Value-added of Industrial Chain

The extension of the industrial chain can not only enhance the market value of products, but also help enterprises form differentiated advantages:

• Pyrolysis Oil: It can produce high value-added non-standard diesel, naphtha, wax oil, etc. through processes such as distillation. Its market application range and commercial value are greater than the initial pyrolysis oil.
• Carbon Black: As an important by-product of pyrolysis products, it can be processed to prepare higher precision carbon black, even rCB through deep processing. It is widely sold to industrial manufacturing, especially recovered tyre.

Disposal Fee Revenue

• In the process of disposing of plastics, oil sludge, and waste tires, environmental protection policies in many regions require them to be harmlessly treated. Many industrial enterprises and government departments often need to pay certain disposal fees when using continuous pyrolysis plant to treat these wastes.
• As the policy of waste recycling and reuse is gradually strengthened, pyrolysis plants can establish long-term cooperative relationships with local governments or related enterprises. This can obtain more disposal contracts, thereby increasing a stable source of income.

Policy-specific Subsidy

• In some regions, pyrolysis projects can obtain special funding support from the government for sustainable projects. These subsidies can not only reduce the initial investment of the project, but also provide financial guarantees for the cost of the pyrolysis plant to help enterprises.
• In addition, some regions have also introduced a series of policies such as tax incentives and land use incentives. Therefore, policy subsidies provide strong financial support for pyrolysis projects, which helps them gain long-term competitive advantages in the market.

Accurate Control of Feeding System

The feeding system consists of a double screw conveyor, a sealed silo, and an electronic weighing system with “gram” level accuracy. This enables precise control of the feed volume. In addition, the system can monitor various indicators during the feeding process in real-time. Thus, this enables periodic statistics of the feed.

Reliable Protection of Nitrogen System

The nitrogen system uses a nitrogen generator with a purity of more than 95%. This device can replace the air in the sealing material bin. During the feeding process, the nitrogen system prevents excess air from entering the reactor with the raw materials. Thus, this maintains an oxygen-depleted environment within the reactor, which makes the pyrolysis process safer.

Precise Adjustment of Reaction Temperature

The induced draft fan reintroduces the high-temperature flue gases into the combustion chamber. At the same time, the high-temperature exhaust gas is mixed with the high-temperature hot air provided by the burner in the combustion chamber. Therefore, the accurate ratio of mixed air volume enables precise adjustment of reaction temperature.

Triple Anti-coking of Reactor

Coking in pyrolysis reactions, especially in oil sludge pyrolysis, seriously affects pyrolysis efficiency. Our equipment applies the following anti-coking methods:

• Reusing high-temperature flue gas reduces the temperature difference of the reactor to prevent coking;
• High-temperature catalyst prevents the material from coking during the rapid reaction time.
• Mesh chain in the furnace contacts and friction with the inner wall of the reactor to physically remove the coke.

Self-cleaning of Three-stage Condenser

Three-stage condenser realizes the separation of heavy impurities and efficient collection of pyrolysis oil. In addition, BLL-30’s condenser uses self-cleaning technology. The oil pump regularly circulates the hot oil in the oil tank to flush the condensation tube in the condenser. This avoids the problem of condensation pipe clogging during long-term use.

Real-time Sampling of Discharge System

The discharge system utilizes a combination sealing design and a water-cooled sealing slag box. It prevents leakage of high-temperature oil and gas during the continuous slag discharge process. Additionally, the discharge head adopts a residue sampling structure. Customers can thus detect the pyrolysis residues in the reactor at different times.

Intelligent Monitoring of Operation

Through PLC control, the system can centrally control parameters such as start and stop, temperature, and pressure of all equipment. At the same time, IoT technology enables real-time remote monitoring of the entire system. Operators can monitor the operating status of the equipment in real-time and make timely adjustments and responses.